Check out how you can repair rusted sheetmetal by using patch panels as shown on this 1969 camaro.
Rust hole repair sheet metal.
And maybe the epoxy would result in a more rustproof seam.
The complexity of welding increases as the thickness of the material decreases.
And butt up to the edges of the hole.
This setup removes the remaining rust and would allow us to cut the hole to an easily patchable size and shape.
Cut the sheet metal back until all of the rust around the hole s perimeter is no longer visible.
The welding process actually adds new steel to the thin steel and can result in a repaired spot that is stronger than the original metal.
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All of the rust must go.
Keep sanding until you re able to see bare metal.
Weld the most permanent repair to a hole in sheet metal is to weld the hole shut.
A rust hole compromises the structural integrity of the metal.
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Then go back toward the center of the hole scrubbing with heavy pressure to eliminate the rust.
The first step was to cut out the rust.
We have a huge selection of high quality rust repair and auto body panels including rockers cab corners wheel arches fenders and more.
Welding in patch panels with a flux core welder without a gas envelope is an exercise in burn through and swearing so glue it was.
Another good idea when replacing any type of sheet metal is using weld through primer.
Two part epoxies are designed for this purpose and when applied to a clean surface the final repair will be undetectable after painting.
Easy to do and really strong.
A plasma cutter reciprocating saw or die grinder can also be used for this step.
To make the repair as effective as possible scrub away the paint up to 1 in 2 5 cm beyond the edges of the hole.
Universal sheetmetal repair panels available at low prices.
Rust on your classic muscle car is a nuisance.